Teardown Page 4
The case can now be stripped of the races and bearings that remain.
Remove the gearbox output shaft roller bearing as shown...
The bellhousing has the input shaft roller bearing, and it is pulled using an internal extractor (not really, read the *edit*). If you do not have an internal extractor, then the bearing can be pressed out from the other side. Remove the filtering screen plate from the case before attaching the puller support...
*edit* -- The factory procedure shows this
internal extractor being used, but the bearing can be knocked out. Remove the
input shaft seal, find a pipe or socket to fit through the trans casing hole,
and knock the bearing out into the trans to remove it.
I showed the tool being used because the Bentley shows it... but while looking at the Bentley just now, I noticed I am using the tool incorrectly, AND, I've damaged the tool as a result! I actually damaged it on another bearing, and learned at that point how to correctly use it, but just realized tonight that this web page shows it being used incorrectly and I figured I'd clarify things :)
I eventually self-taught myself the correct way
to use the tool, but not until I had damaged it. At least I learned from my
mistake... notice in my pics I insert the tool into the bearing and through it
nearly, grabbing the backside of the bearing... if you aren't careful, you'll
get the puller between the casing and the rollers, and you'll be pulling on the
rollers. The bearing is being replaced so it won't matter if the rollers are
hurt, but they are tough. Very tough. Notice a couple pics below the end of one
of the 3 puller arms looks notched, it has chunks missing out of the edge.
Notice those chunks are just about perfectly lined with the rollers in that
bearing? The rollers will break your tool... I think I did that on the 5th
housing support bearing, but these pics show it being used incorrectly.
If you had to use this tool, in the pic below (pretending it was an actual blind-hole bearing you couldn't get behind), you would insert the tool JUST under the top of the rolled over outer race body. The puller would be ABOVE the rollers. This would be a better tool-to-bearing contact and you won't break your tool... like I did. That stupid thing is about $80 too!
The (damaged but still working) internal extractor opens up as shown to grab the bearing...
Pull the output shaft small bearing outer race from the bellhousing as shown here...
Make sure that the pulling hooks of the internal extractor are in this position, so they are able to fit under the bearing race...
There is a small section in the bottom of the bore that the race sits on, this is higher than the bottom of the bore, allowing the extractor hooks to grab....
The diff carrier bearing races are pressed out of the case the same way basically, this shows the gear box side being removed, VW554 fits into the hole and just catches the race...
I'll add more pics later of the seals being removed and the green seal sleeve and 5th end cap being removed, but they basically pry out and are replaced with new.
The trans should now be stripped for most repairs that you would want to do.
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